Illumination control means



July4, 1944- H. R ANNls v 2,352,679

' H ILUMINATIONv CONTROL MEANS Filed July 7, 1942 2 sheets-sheet 1 Patented July 4, 1944 ILLUMINATION CONTROL MEANS Howard Russell Annis, Mount Holly, N. J., asi signor to Arrow Safety Device Company, Medford,`N. J., a corporation of New Jersey Application July 7, 1942, Serial No. 450,1'40

7 Claims.

This invention relates to illumination control means and has particular reference to lamp relays adapted to be associated with such lamps as the headlamps of motor vehicles.

Present day headlamp filaments draw very heavy currents for their rated operation from a source of relatively low voltage comprising, for example, the usual combination of a storage battery and charging generator. Since these headlamps are located in the front of the vehicle, the battery, in some location such as under the rear of the hood or under a seat or iioor boards, and the control switch on the instrument panel or elsewhere accessible to the operator, the total length of electrical wiring involved provides in the filament circuit av resistance which, though small in value, provides an RI drop which reduces the voltage at the filament to an amount quite appreciably less thanfthe voltage of the supply, The candle power of a lamp falls off very rapidly with decrease of the filament voltage, and as a consequence, the ordinary connections, even dis- Y regarding resistance at the switch contacts, result in an appreciable dimming of the VIilaments below' their normal intensity, with a waste of electrical energy in the incidental resistances in the way of dissipated heat. y resistance at the switch provides an RI drop still further reducing the voltage. Generally speaking, it is not feasible to correct this condition by r providing suflciently massive contact'elements at the switch and by providing connecting `cable of sufiiciently large gage. V Y Y vAs a consequence of this condition, 'it is common to provide lamp relays 'at positions closely adjacent the lamps, whichy relays are of vsuchl type that they may be energized with relatively low currents, while their armatures close massive cntacts'directly between heavy connections to the/battery and to the lamp lament. Generally speaking, the connection from the battery to the relay is the longest one, but if a suitable relay is provided, only a single connecting cable is necessitated through the major or the entire distance involved to provide current tol all four of the usual headlamp filaments. Thisl cable may Additionally, the

be very heavy, since there is not involvedV any question of threading a plurality of cabl'e'sfto a suitable switching meansin the Ivicinity off the driver;V The connecting wires'for the energication of the relays may be of quite small `gage suitable to carry the small currents involved.

V-The disadvantage of an arrangement of ythe type just described is that its installation genere ally involves the mechanicaloperationfof drilling and tapping holes in suitable portions of the vehicle frame to carry the relays, while additionally the original wiring connections must be disturbed and new ones made.

The broad object of the present invention may be stated to be the provision of such a headlamp relay arrangement the installation of which is extremely easy, particularly when the headlamps are of the so-called sealed beam type in which the bulb is normally secured in position about its periphery and presents rearwardly extending prongs of quite rigid construction adapted to be engaged by a connector which is normally supported thereby. In accordancewith the invention, a relay assembly is provided which may be mounted directly upon the prongs whichv serve not only for electrical connections, but, through their rigidity, as substantial andv adequate supports for the relay assembly.` Additionally, the relay assembly carriesprongs which may be engaged by the connector theretofore engaging the prongs of the lamp, there being provided in this fashion suitable control` connections. For the completion of the installatiomthe sole additional matter to be provided is a heavy cable to run directly from the batteryto each of the relay assemblies.

The general object of the invention, and other objects, particularly relating to details, will become apparent from `the following description, read in conjunction with the accompanying drawings, in which: I

Figure lis a vertical sectional view showinga headlamp andv relay assembly in side elevation;

Figure v2 is arearelevationof the same, partially in section, to show the interior of the relay assembly; "i

Figure 3 is a wiring diagram ofthe modification of Figures 1 and2;`

Figure 4 is a rear elevation -of a modied form of relay assembly; and

Figure 5 isa wiring `diagram showing the connections involved in the assembly of Figure 4.

Referring first to Figures 1 and 2 and the wir ing diagram" of Figure 3, there is illustrated'at 2 one of the fenders of an automobile in which there is mount'edtaheadlainp ofthe Sealed beam variety by the use'of la'rfannular ring 'arrangement indicated at Vii. lifeadlanips"oi :this type .are provided with -relatively'rigid' prongs; indi# cated at', IE! and i2. 4I-Zeadlamps of Vvthis type are Vgenerally provided with twoflainents corn monly-designated as producing bright and dini beams, though quite' generally thesetwo 'la ments Vare identical andthe diiness or brightness involved is merely that apparent to someone approached by the vehicle depending upon which of the beams is directed upwardly and which is directed downwardly, the downwardly directed beam being designated the dim one. For the purpose of the present matter, however, it may be considered that the terms dim and bright may apply` either to the apparent effects or to the relative candle powers involved. In the case of thedim beam, generally used for city driving, the intensity is not particularly important, and a reduction of its candle power due to resistance of connections is not serious, so that in the case of the dim beam,v the association therewith of a relay may be dispensed with. In the case of the bright beam, however, a relay is desirable, and in the modication of Figures 1, 2 and 3, the relay is arranged vv'for the control of the bright beam only. It will be understood, of course, that each of the headlamps has its individual relay.

The relay assembly for each lamp comprises a base which may be molded as a unit or built up of various sections of a plastic insulating material, which may be opaque or transparent, depending upon whether it is desirable to see the actionV of the relay during testing without dismantling. The specic way in which this base is built up is immaterial and subject to large variation, and consequently, it need not be described Vin any detail. It may be stated, however, that it comprises a central portion I4, and, desirably, two portions I6 and I8 extending adjacent the reflector portion of the lamp to conserve space. The central portion I4 is provided with a plurality of spring contacts designed to t upon and engage the prongs 8, I'0 and I2. These are of. conventional'connector type and are indicated as spring contacts in the wiring diagram of Figure 3. A relay is carried by the extension I6 of the base, and is indicated at 28, being provided with an armature 25 adapted to be attracted upon energization of the relay to close contacts at 2I and 23, respectively. The portion I8 of the base is provided with a set of prongs, indicated at 22, 24 and 25, and having the same geometrical form as the assembly of prongs 8, I and I2. These last named prongs are adapted to be engaged by the conventional connector 28, which, if the relay was not used, would engage the prongs 8, I8 and I2 to eiiect the proper connections to the switching means. One of the spring -contacts within the connector 28is grounded in conventional fashionby awire 30, which may be; electrically connected to the mounting ofthe lamp. .Y 1 g As will be seen from Figure 2, the base 'of the assembly carries various permanent wire connections between the prongs, relay armature, contact points and sockets. The physical arrangement of these is, of course, subject to Wide variation, but the electrical conguration may be best madeclear by reference to Figure 3.

A; source of current is conventionalized Yin Figure 3 as a battery 38, though it will be understood that this consists in the usual fashion of a combination of battery and charging generator. One pole of this batteryris grounded.V rIhe other pole is connected toY the switch 4I), manually operable by a driver, between two contact points` 42 and 44, the former representing control of the bright filaments and the latter of the dim filaments. As indicated above, this assemf bly needl not be disturbed if the change is made from aconventional arrangement toone involving the relay. The spring Contact sockets'in the connector 28 are joined, respectively, to the points 42, 44 and ground, as illustrated.

The dim lament is indicated at 34 and the bright filament at 36. Prong I0 is the ground prong of the lamp, while 8 is connected to the dim lament and I2 to the bright one. The spring sockets carried by the base engage these prongs as indicated in'thefigure, wherein there are also indicated the connections vto the relay 2U and the contact points 2l and 23 adapted to be bridged by the armature. The contact point 23 is connected directly to the ungrounded side of the source 38 by a heavy cable with the interposition of a suitable fuse, indicated at 32 and conventionally carried on the relay assembly as indicated in Figure 2.

It'will be evident that if the switch 40 makes contact at 42, the relay 20 will be energized and the circuit closed through the bright lament 36, there being in this circuit only the massive relay contacts, the heavy cable from the battery and the fuse 32. If the switch 4Q is thrown to the position 44, however, the dim filament is energired, the current flowing in conventional fashion except for its passage between 22 and 8 through a wire carried by the base. YThe varrangement is essentially duplicated for the other headlamp, there being either` independent heavy cables running from the battery or a single. cable connected to branches at the irontV ofthe vehicle in the vicinity of the headlamps. y

The same fundamental mattersmay 4be involved in the control of current through bothY laments by relays. Figure 4 illustrates adual relay assembly for this purpose which is wired up as indicated in Figure 5. In the caseof IFigure 4, the prongs 46, 48 and 50 correspond to the prongs 26, 22 and 24, of Figure 3. Twov relays 52 and 56 are provided with respective armatures y' 54 and58. These are mounted on a base consisting of a central portion 62, a' pair of wings. 64and 66 carrying the relays and an extension 68 carrying the prongs 46, 48 and 5I). The central portion 62 is provided with sockets adapted to receive the prongs on the lamp. A fusemay be mounted on the base, being connected between the relay contact points, and the cableto the source. i I

The operation of the modification will be quite evident from Figure 5, in which the assembly of Figure 4 is shown substituted for the assembly of Figures 1 and 2 in the same generalcircuit as that previously described. It will begevident that in this case the'switch energizes Vthe relays selectively; 1 i" I f -V It will-'be evident that in accordance with-the invention,the specific embodiments thereof, may be of various forms. For example,vif the headlamps are -offa different ty1: e,the-relay mount? ing basev may bey madeto correspond, so that if; for example, sockets are provided ron the head-f,Y lamps Ato lreceive prongs extending from a con-l nector normally used, the relay bases would vbe provided with prongs to complete-theelectrical circuits andto serve for mechanical support. ,y It

' will be evident, furthermore, that the wiring-ar` rangements may be substantially ychanged witho ut departing Afrom thescope of the invention; 'r

What I claim and desire Patent is: i

1..In combination, a lamp vzofvv the typel ar-. ranged to be supported by means engagingiits circumference and yprovided with substantially to protect by Letters` rigid prongs I electricallyconnected to at least' y one filament thereof, a connector of a type adapted to engage said prongs to provide an electrical connection therewith, and a relay assem-bly,

the base and engageable with said prongs tosupport said assembly thereon, and prongs carried by said base and engageable by saidconnector. and electrical connections between the aforesaid parts of the assembly so that the relay may be energized by current flowing between said connector and at least one of said prongs carried'v by the base, and the lamp filament may be energized upon operation of the relay through current flowing between at least one of the contact* elements carried by the base and the correspond:`

ing prong of the lamp.

2. In combination, a lamp of the type arranged to be supported by means engaging its circumference and provided with at least one substantially rigid prong electrically connected to at least one filament thereof, a connector of a type Vadapted to engage said prong to provide an electrical connection therewith, and a relay assem- -bly, said relay assembly comprising a base, a relay having an electromagnet and circuit closing means engageable upon energization of the electromagnet, at least one contact element carried by the base and engageable with said prong to support said assembly thereon, and at least one prong carried by said base and engageable by said connector, and electrical connections between the aforesaid parts of the assembly so that the relay `may be energized by current flowing between said connector and said prong carried by the base, and the lamp filament may be energized upon operation of the relay through current ilowing between at least one of the contact elements carried by the base and said prong of the lamp.

3. In combination, a lamp of the type arranged to be supported by means engaging its circumference and provided with at least one connector element electrically connected to a filament thereof, a connector of a type adapted to engage said connector element to provide an electrical connection therewith, and a relay assembly, said relay assembly comprising a base, a relay having an electromagnet and circuit closing means engageable upon energization of the electromagnet, at least one connector element carried by the base and engageable with the connector element of the lamp to support said assembly thereon, at least one connector member carried by said base and engageable by said connector, and electrical connections between the aforesaid parts of the assembly so that the relay may be energized by current flowing between said connector and said connector member car- Y said relay assembly comprising a base,` a relay having an electromagnet and circuitv closingy means engageable upon energization of-` the electromagnet, contact elements carried byv tromagnet, and at least one connector element' carried by the base, connected to said circuit closing means, and engageable with the connector element of the lamp to support said assembly thereon. i

5. A relay assembly designed for association with a lamp of the type provided with at least one prong electrically connected to a lament thereof and arranged to be supported by `means engaging its circumference, comprising a base, a relay carriedby said base and comprising an electromagnet and circuit closing means engageable upon energization of the electromagnet, and at least one connector element carried by the base, connected to said circuit closing means, and engageable with the prong of the lamp to support said assembly thereon.

6. A relay assembly designed for association 'with a lamp of the type provided with at least one connector element electrically connected to a filament thereof and arranged to be supported by means engaging its circumference, comprising a base, a relay carried by said base and cornprising an electromagnet and circuit closing means engageable upon energization ofthe electromagnet, at least one connector element carried by the base, connected to said circuit closing means, and engageable with the connector element of the lamp to support said assembly thereon, and a connector member on the base electrically joined to the electromagnet and through which said electromagnet may be energized.y

7. A relay assembly designed for association with a lamp of the type provided with at least one prong electrically connected to a lament l thereof and arranged to be supported by means 

